Why predictive maintenance is becoming a core safety strategy for MRO teams
Key Highlights
- Digital tools and wearables support technicians by providing real-time risk management and boosting productivity in hazardous environments.
- Innovations in lockout/tagout procedures digitize safety steps, improving compliance and reducing manual errors during energy isolation tasks.
- Predictive maintenance uses sensors and algorithms to forecast failures, enabling safer interventions and minimizing emergency repairs.
- Connected OT and IT systems introduce cybersecurity risks, emphasizing the need for comprehensive safety and security strategies.
- Modern maintenance safety relies on technology, data integration, and adaptive training to address systemic risks and workforce challenges.
MRO teams are being asked to do more with less, and maintain uptime, respond faster, and manage increasingly complex equipment, all while operating in some of the most hazardous areas of industrial facilities.
From energized equipment and stored energy to time-critical repairs in confined spaces, maintenance work exposes technicians to risks that are both persistent and evolving. Insights from industrial equipment distributor Global Industrial Company leadership show that as equipment and workflows grow more complex, maintenance safety must become more integrated and predictive.
Maintenance teams are under growing pressure
One of the defining challenges shaping maintenance safety today is workforce strain. Labor shortages have increased reliance on smaller teams of multi-skilled technicians who are expected to handle a wider range of tasks, often under tight timelines.
“Technology is helping to offset some of these issues in real time with either a digital solution, an app, or a wearable solution,” says Heather Lake, director of product management at Global Industrial. These tools are increasingly used to support technicians in the field, helping them manage risk while maintaining productivity.
At the same time, industrial equipment is becoming more connected and complex. Robotics, sensors, and intelligent systems are changing how maintenance is performed, raising new safety considerations alongside traditional physical hazards.
Reducing human error through digital processes
As safety programs become more data-centric, organizations are also targeting manual processes that have historically introduced risk. One area seeing rapid innovation is lockout/tagout (LO/TO), a critical safety procedure for controlling hazardous energy during maintenance activities.
“Stored energy and electrical exposure continue to pose a high risk in manufacturing facilities today,” Lake says. While lockout/tagout procedures are well established, reliance on manual steps and paper-based tracking can leave room for error or non-compliance.
To address this gap, new digital lockout/tagout solutions are being introduced. “There are new innovations that are currently being brought to market in lockout/tagout devices,” Lake explains. “These will take this manual process to a digital form that will ensure higher compliance with safety standards and reduce human error.”
By digitizing verification, documentation, and accountability, these systems help ensure that critical safety steps are followed consistently, particularly in maintenance-heavy environments where multiple workers and shifts may be involved.
For maintenance teams, safety measures must support the work, not slow it down. Tools that add friction or complexity are less likely to be followed, especially in time-sensitive situations.
“The idea behind risk mitigation products is that they flow seamlessly into the maintenance workflow without causing disruption,” Lake says. When safety tools align with how maintenance teams operate, they are more likely to improve both protection and efficiency.
Many risk mitigation products provide real-time visibility into safety status, enabling supervisors and technicians to understand conditions without relying on manual checks. This same accountability can also lead to increased productivity.
Predictive maintenance supports safer interventions
Maintenance safety is also being influenced by the growing use of predictive and condition-based tools. “Maintenance teams are using digital tools, sensors, and predictive technologies to gain real-time insights and reduce unplanned downtime,” Lake says. Condition-monitoring sensors track factors such as vibration, temperature, and pressure, while predictive algorithms analyze this data to forecast potential failures.
“Smart alerts notify teams when equipment performance exceeds safe thresholds, allowing for quick, informed responses,” Lake adds. By reducing emergency repairs and unplanned shutdowns, predictive maintenance can lower the safety risks associated with reactive work.
Digital dashboards and integration with maintenance systems further support this approach by improving work order planning and asset visibility.
Expanding risk landscape for MRO teams: rethinking maintenance safety
Beyond physical hazards, maintenance safety now includes a broader set of systemic risks. As operational technology (OT) becomes more connected to information technology (IT) networks, cybersecurity concerns can directly affect equipment reliability and safe operation.
“Cyber risks are rising as OT systems link with IT networks, exposing critical equipment to potential attacks,” Lake says. Human factors also remain a major concern, particularly fatigue and communication breakdowns in environments that increasingly rely on robotics and automation.
Many facilities continue to face challenges related to data silos and limited real-time visibility, making it harder to anticipate problems before they affect safety. Workforce gaps and evolving regulatory requirements continue to add further complexity.
As Lake summarizes, “Safety today requires foresight, digital fluency, and adaptive training to keep pace with technology and ensure resilient, error-resistant maintenance environments.”
In high-risk, high-complexity manufacturing environments, maintenance safety must evolve alongside the work itself. Modern maintenance safety extends beyond procedures and PPE. It depends on the systems and technology that support technicians in real time, reduce reliance on manual processes, and anticipate risk before conditions escalate.
About the Author
Anna Townshend
managing editor
Anna Townshend has been a journalist and editor for almost 20 years. She joined Control Design and Plant Services as managing editor in June 2020. Previously, for more than 10 years, she was the editor of Marina Dock Age and International Dredging Review. In addition to writing and editing thousands of articles in her career, she has been an active speaker on industry panels and presentations, as well as host for the Tool Belt and Control Intelligence podcasts. Email her at [email protected].